Surgical stapling device with replaceable staple cartridge

ABSTRACT

A surgical stapling device includes a tool assembly having an anvil assembly and a cartridge assembly. The anvil assembly includes a staple deforming surface and defines an elongate channel that supports a roller. The staple deforming surface defines a transverse slot. The roller supports a buttress material that can be pulled through the transverse slot to position the buttress material atop the staple forming surface.

FIELD

This technology is generally related to surgical stapling devices and, more particularly, to surgical stapling devices with replaceable staple cartridges.

BACKGROUND

Surgical stapling devices for endoscopic use are well known and commonly used to minimize patient trauma and reduce patient recovery times. Typically, endoscopic stapling devices include a tool assembly that has an anvil assembly and a cartridge assembly that are coupled to each other by a pivot member and movable in relation to each other between open and clamped positions. The cartridge assembly includes a channel member that supports a staple cartridge. In order to facilitate reuse of the surgical stapling device, the staple cartridge of the tool assembly may be replaceable. These replaceable staple cartridges are referred to as multiple use loading units or MULUs. In such devices, the anvil assembly is reused with each of the MULUs.

In some stapling devices, the staple cartridge and/or the anvil assembly include a buttress material that is supported on the anvil assembly and/or the cartridge assembly to reinforce the staple line applied to tissue. When a MULU is used with a stapling device, the buttress material must be replaced on the anvil assembly after each firing of the stapling device. Typically, the buttress material on the anvil assembly is manually replaced by a clinician in the operating room. This requires a lot of time and effort and increases the length of the surgical procedure.

A continuing need exists in the art for a surgical stapling device that allows the buttress material on the anvil assembly to be easily and quickly replaced after each firing of the stapling device.

SUMMARY

This disclosure is directed to a surgical stapling device that includes a tool assembly having an anvil assembly and a replaceable cartridge assembly. The anvil assembly includes a staple deforming surface and defines an elongate channel that supports a roller. The staple deforming surface defines a transverse slot. The roller supports a buttress material that can be pulled through the transverse slot to position the buttress material atop the staple forming surface after each firing of the stapling device.

Aspects of this disclosure are directed to a tool assembly including an anvil assembly and a cartridge assembly. The anvil assembly includes an anvil member and an anvil base. The anvil member includes an inner staple forming surface and an outer surface. The outer surface defines an elongate channel. The anvil member is secured to the anvil base to enclose the elongate channel. The anvil member includes at least one roller that is positioned within the elongate channel. The at least one roller supports a buttress material that is rolled about the at least one roller. The anvil member has a distal portion that defines at least one transverse slot that extends through the anvil member and communicates with the elongate channel. The buttress material has a first end that extends through the transverse slot and is movable through the at least one transverse slot to a position atop the staple forming surface. The cartridge assembly is movably supported in relation to the anvil assembly such that the tool assembly is movable between an open position and a clamped position. The cartridge assembly includes a channel member and a staple cartridge that is removably supported within the channel member. The staple cartridge is in juxtaposed alignment with the staple forming surface of the anvil assembly when the tool assembly is in the clamped position.

Other aspects of this disclosure are directed to a surgical stapling device including a handle assembly, an elongate body, and a tool assembly. The elongate body has a proximal portion coupled to the handle assembly and a distal portion. The tool assembly is supported on the distal portion of the elongate body and includes an anvil assembly and a cartridge assembly. The anvil assembly includes an anvil member and an anvil base. The anvil member includes an inner staple forming surface and an outer surface. The outer surface defines an elongate channel. The anvil member is secured to the anvil base to enclose the elongate channel. The anvil member includes at least one roller that is positioned within the elongate channel. The at least one roller supports a buttress material that is rolled about the at least one roller. The anvil member has a distal portion that defines at least one transverse slot that extends through the anvil member and communicates with the elongate channel. The buttress material has a first end that extends through the transverse slot and is movable through the at least one transverse slot to a position atop the staple forming surface. The cartridge assembly is movably supported in relation to the anvil assembly such that the tool assembly is movable between an open position and a clamped position. The cartridge assembly includes a channel member and a staple cartridge that is removably supported within the channel member. The staple cartridge is in juxtaposed alignment with the staple forming surface of the anvil assembly when the tool assembly is in the clamped position.

Other aspects of the disclosure are directed to an anvil assembly that includes an anvil member and an anvil base. The anvil member includes an inner staple forming surface and an outer surface. The outer surface defines an elongate channel. The anvil member is secured to the anvil base to enclose the elongate channel. The anvil member includes at least one roller that is positioned within the elongate channel. The at least one roller supports a buttress material that is rolled about the at least one roller. The anvil member has a distal portion that defines at least one transverse slot that extends through the anvil member and communicates with the elongate channel. The buttress material has a first end that extends through the transverse slot and is movable through the at least one transverse slot to a position atop the staple forming surface.

In aspects of this disclosure, the at least one roller includes first and second rollers and the at least one transverse slot includes first and second transverse slots.

In some aspects of this disclosure, the anvil member includes a proximal portion that defines a transverse channel, and the first end of the buttress material is received within the transverse channel when the buttress material is extended across the staple forming surface of the anvil member to secure the first end of the buttress material to the anvil member.

In certain aspects of this disclosure, a cap is supported on the anvil member and is movable from an open position to a closed position to provide access to the at least one roller and the buttress material.

In aspects of this disclosure, the cap includes a distal portion that is pivotably coupled to the anvil member.

In some aspects of this disclosure, the cap includes a proximal surface that defines the at least one transverse slot, and proximal surface of the cap engages the buttress material in its closed position to secure the buttress material to the anvil member.

In certain aspects of this disclosure, the rollers are supported for rotation within the elongate channel.

In aspects of this disclosure, the rollers are fixedly supported within the elongate channel.

Other features of the disclosure will be appreciated from the following description.

BRIEF DESCRIPTION OF DRAWINGS

Various aspects of the disclosure are described herein below with reference to the drawings, wherein:

FIG. 1 is a side perspective view of a surgical stapling device including an anvil assembly according to aspects of the disclosure with a tool assembly of the surgical stapling device in an open position;

FIG. 2 is an enlarged view of the indicated area of detail shown in FIG. 1;

FIG. 3 is a side perspective view of the tool assembly shown in FIG. 1;

FIG. 4 is a perspective exploded view of the anvil assembly of the tool assembly shown in FIG. 3;

FIG. 5 is an enlarged view of the indicated area of detail shown in FIG. 4;

FIG. 6 is a cross-sectional view taken along section line 6-6 of FIG. 3;

FIG. 7 is an enlarged view of the indicated area of detail shown in FIG. 6;

FIG. 8 is an enlarged view of the indicated area of detail shown in FIG. 6;

FIG. 9 is a side perspective view of the tool assembly shown in FIG. 3 with a staple cartridge of the tool assembly removed prior to application of a buttress material to the anvil assembly;

FIG. 10 is a cross-sectional view taken along section line 10-10 of FIG. 9;

FIG. 11 is a cross-sectional view taken along section line 10-10 of FIG. 9 as the buttress material is applied to the anvil assembly;

FIG. 12 is a side perspective view of the tool assembly shown in FIG. 3 with the staple cartridge of the assembly removed and the buttress material applied to the anvil assembly;

FIG. 13 is a side perspective view of another version of the tool assembly of the surgical stapling device shown in FIG. 1 with the staple cartridge removed and a roller cap closed; and

FIG. 14 is an enlarged view of a distal portion of an anvil assembly of the tool assembly shown in FIG. 13 with the roller cap open.

DETAILED DESCRIPTION

The disclosed surgical stapling device will now be described in detail with reference to the drawings in which like reference numerals designate identical or corresponding elements in each of the several views. However, it is to be understood that the aspects of the disclosure are merely exemplary of the disclosure and may be embodied in various forms. Well-known functions or constructions are not described in detail to avoid obscuring the disclosure in unnecessary detail. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the disclosure in virtually any appropriately detailed structure. In addition, directional terms such as front, rear, upper, lower, top, bottom, distal, proximal, and similar terms are used to assist in understanding the description and are not intended to limit the disclosure.

In this description, the term “proximal” is used generally to refer to that portion of the device that is closer to a clinician, while the term “distal” is used generally to refer to that portion of the device that is farther from the clinician. In addition, the term “endoscopic” is used generally used to refer to endoscopic, laparoscopic, arthroscopic, and/or any other procedure conducted through a small diameter incision or cannula. Further, the term “clinician” is used generally to refer to medical personnel including doctors, nurses, and support personnel.

FIG. 1 illustrates exemplary aspects of the disclosed surgical stapling device shown generally as stapling device 10. The stapling device 10 includes a handle assembly 12, an elongate body 14 defining a longitudinal axis “X” (FIG. 1), and a tool assembly 16. The handle assembly 12 includes a stationary handle 18 and a trigger 20 that is movable in relation to the stationary handle 18 to actuate the tool assembly 16. In aspects of the disclosure, the stapling device 10 includes a rotation knob 22 and an articulation lever 24. The rotation knob 22 is coupled to the handle assembly 12 and supports the elongate body 14 to facilitate rotation of the elongate body 14 and tool assembly 16 in relation to the handle assembly 12 about the longitudinal axis “X”. The articulation lever 24 is coupled to the tool assembly 16 to articulate the tool assembly 16 from a position aligned with the longitudinal axis “X” to positions defining acute angles with the longitudinal axis “X”. In some aspects of the stapling device 10, the handle assembly 12 includes retraction knobs 26 for retracting a drive assembly (not shown) of the stapling device 10. For a more detailed description of exemplary aspects of the handle assembly 12 of the stapling device 10, see, e.g., U.S. Pat. No. 6,241,139. Although the handle assembly 12 is illustrated as a manually operated handle assembly, it is envisioned that the handle assembly 12 could be a powered handle assembly such as described in U.S. Pat. No. 9,055,943.

FIGS. 2 and 3 illustrate the tool assembly 16 of the stapling device 10 (FIG. 1). The tool assembly 16 includes an anvil assembly 28 and a cartridge assembly 30 that are movable in relation to each other between an open position (FIG. 2) and a clamped position. In aspects of the disclosure, the anvil assembly 28 and the cartridge assembly 30 are coupled together with pivot members 32 such that the cartridge assembly 32 can pivot in relation to the anvil assembly 30 between an open position (FIG. 1) and a clamped position. Although the cartridge assembly 30 is illustrated as pivoting towards a stationary anvil assembly 28, it is envisioned that the anvil assembly 30 could be adapted to pivot towards a stationary cartridge assembly 30.

The cartridge assembly 30 includes a channel member 32 and a staple cartridge 34. The channel member 32 defines a cavity 36 (FIG. 9) that receives the staple cartridge 34 such that the staple cartridge 34 can be replaced after each firing to facilitate reuse of the stapling device 10 (FIG. 1).

FIGS. 4-8 illustrate the anvil assembly 28 which includes an anvil base 36 and an anvil member 38. The anvil base 36 includes a proximal portion 40 and a distal portion 42 and includes a staple forming surface 44 (FIG. 9). The staple forming surface 44 defines a central knife slot 46 and a plurality of staple forming pockets 48 (FIG. 9) positioned on each side of the staple forming surface 44. In aspects of the disclosure, the staple forming pockets 48 are aligned in rows on each side of the central knife slot 46. Although the staple forming surface 48 is illustrated as having three rows of staple forming pockets 48, it is envisioned that the staple forming surface 44 can include one or more rows of staple forming pockets or other arrays of staple forming pockets 48.

The anvil base 36 includes an outer surface opposite to the staple forming surface 44 that defines an elongate channel 50 that communicates with the central knife slot 46. The elongate channel 50 is configured to receive an upper beam (not shown) of a drive assembly (not shown) of the stapling device 10. The elongate channel 50 includes a distal portion that includes two posts or rollers 52 (FIG. 5) that extend transversely across the elongate channel 50. Each of the rollers 52 can be supported on the anvil member 38 for rotation within the elongate channel 50. Alternately, the rollers 52 can be fixedly mounted to the anvil member 38 within the elongate channel 50. Although the anvil base 36 is illustrated to have two rollers 52, it is envisioned that the anvil base 36 can include one or more rollers 52.

The anvil base 36 includes a proximal portion 60 and a distal portion 62 FIG. 4). The proximal portion 60 includes spaced flange portions 64 and a proximally extending bracket 68 (FIG. 5). The spaced flange portions 64 include openings 66 and the proximally extending bracket 68 defines an opening 70. The bracket 68 is coupled to the stapling device 10 (FIG. 1) to facilitate articulation of the tool assembly 16 in relation to the elongate body 14. The openings 66 in the spaced flange portions 64 receive the pivot members 32 to pivotably couple the anvil assembly 28 to the cartridge assembly 30. The anvil base 36 includes an elongated spine 72 that extends from the proximal portion 60 of the anvil base 36 to the distal end of the distal portion 62 of the anvil base 36.

The anvil base 36 is secured to the anvil member 38 such the spine 72 encloses the elongate channel 50. The distal portion of the anvil member 38 defines two transverse slots 74 (FIG. 7) that extend through the distal portion of the anvil member 38 and communicate with the elongate channel 50. Each of the rollers 52 supports a roll of buttress material 80 that has a first end 80 a that extends from a respective one of the transverse slots 74 and can be unrolled over the staple forming surface 44 of the anvil member 38. The anvil member 38 defines a transverse channel 82 (FIG. 8) that is positioned at the proximal end of the staple forming surface 44 and receives the first end 80 a of the roll of buttress material 80 when the buttress material 80 is extended over the staple forming surface 44. Receipt of the first end 80 a of the buttress material 80 within the transverse channel 82 secures the first end 80 a of the buttress material 80 to the staple forming surface 44 of the anvil member 38. In aspects of the disclosure, the transverse channel 82 can be angled towards the distal end of the anvil assembly 28 to define with the longitudinal axis “X” an angle β (FIG. 8), wherein β is from about 60 degrees to about 80 degrees. Alternately, other devices or techniques can be used to secure the first end 80 a of the buttress material 80 to the anvil member 38.

FIGS. 9 and 10 illustrate the tool assembly 16 after the stapling device 10 is fired and the staple cartridge 34 is removed from the channel member 34 of the cartridge assembly 30. In this position, the buttress material 80 is rolled about the rollers 52 and the first end 80 a of the buttress material 80 extends from a respective one of the transverse slots 74 defined in the distal portion of the anvil member 38.

FIGS. 11 and 12 illustrate the tool assembly 16 of the stapling device 10 as the buttress material 80 is placed onto the staple forming surface 44 of the anvil assembly 28. In order to place the buttress material 80 onto the staple forming surface 44 of the anvil assembly 28, a clinician grasps the first end 80 a of the buttress material 80 and pulls the buttress material 80 through the transverse slot 74 in the direction of arrow “A” in FIG. 11 across the staple forming surface 44 of the anvil member 38. When the first end 80 a is positioned adjacent the transverse channel 82 (FIG. 8), the first end 80 a of the buttress material 80 is inserted into the transverse channel 82 to secure the first end of the buttress material 80 to the anvil member 38.

FIGS. 13 and 14 illustrate an alternate version of the anvil assembly of the stapling device 10 (FIG. 1) shown generally as anvil assembly 128. The anvil assembly 128 is substantially similar to the anvil assembly 28 (FIG. 11) except that the anvil assembly 128 includes a single roller 152, a single transverse slot 174 and a cap 190 that is secured to the distal position of the anvil member 138 of the anvil assembly 128. The cap 190 has a distal portion 192 that is pivotably coupled to the anvil member 128 about a pivot member 196. The cap 190 has a proximal surface 198 that defines the proximal end of the transverse slot 174 and is pivotable between an open position (FIG. 14) to provide access to the roller 152 and the buttress material 180 and a closed position (FIG. 13) in which the buttress material 180 is clamped between the proximal surface 198 of the cap 190 and the surface 200 of the anvil member 138 that defines the proximal end of the transverse slot 174. When the cap 190 is in the closed position, the buttress material 180 is secured to the distal portion of the anvil forming surface 144. It is envisioned that or retaining structure could be provided to secure the buttress material 180 to the distal portion of the anvil forming surface 144.

Persons skilled in the art will understand that the devices and methods specifically described herein and illustrated in the accompanying drawings are non-limiting exemplary aspects of the disclosure. It is envisioned that the elements and features illustrated or described in connection with one exemplary aspect of the disclosure may be combined with the elements and features of another without departing from the scope of the disclosure. As well, one skilled in the art will appreciate further features and advantages of the disclosure based on the above-described aspects of the disclosure. Accordingly, the disclosure is not to be limited by what has been particularly shown and described, except as indicated by the appended claims. 

What is claimed is:
 1. A tool assembly comprising: an anvil assembly including an anvil member and an anvil base, the anvil member including an inner staple forming surface and an outer surface, the outer surface defining an elongate channel, the anvil member secured to the anvil base to enclose the elongate channel, the anvil member including at least one roller positioned within the elongate channel, the at least one roller supporting a buttress material that is rolled about the at least one roller, the anvil member having a distal portion that defines at least one transverse slot that extends through the anvil member and communicates with the elongate channel, the buttress material having a first end that extends through the transverse slot, the buttress material being movable through the at least one transverse slot to a position atop the staple forming surface; and a cartridge assembly movably supported in relation to the anvil assembly such that the tool assembly is movable between an open position and a clamped position, the cartridge assembly including a channel member and a staple cartridge removably supported within the channel member, the staple cartridge being in juxtaposed alignment with the staple forming surface of the anvil assembly when the tool assembly is in the clamped position; a cap supported on the anvil member, the cap being movable from an open position to a closed position to provide access to the at least one roller and the buttress material, the cap including a distal portion that is pivotably coupled to the anvil member, wherein the cap includes a proximal surface that defines the at least one transverse slot, the proximal surface of the cap engaging the buttress material in its closed position to secure the buttress material to the anvil member.
 2. A surgical stapling device comprising: a handle assembly; an elongate body having a proximal portion and a distal portion, the proximal portion coupled to the handle assembly; and a tool assembly supported on the distal portion of the elongate body, the tool assembly including: an anvil assembly including an anvil member and an anvil base, the anvil member including an inner staple forming surface and an outer surface, the outer surface defining an elongate channel, the anvil member secured to the anvil base to enclose the elongate channel, the anvil member including at least one roller positioned within the elongate channel, the at least one roller supporting a roll of buttress material that is rolled about the at least one roller, the anvil member having a distal portion that defines at least one transverse slot that extends through the anvil member and communicates with the elongate channel, the buttress material having a first end that extends from the roll of buttress material through the transverse slot, the buttress material being withdrawn from the roll of buttress material and movable through the at least one transverse slot to a position atop the staple forming surface; a cartridge assembly movably supported in relation to the anvil assembly such that the tool assembly is movable between an open position and a clamped position, the cartridge assembly including a channel member and a staple cartridge removably supported within the channel member, the staple cartridge being in juxtaposed alignment with the staple forming surface of the anvil assembly when the tool assembly is in the clamped position; and a cap supported on the anvil member, the cap being movable from an open position to a closed position, to provide access to the at least one roller and the buttress material, the cap including a distal portion that is pivotably coupled to the anvil member and a proximal surface that defines the at least one transverse slot, the cap engaging the buttress material in the closed position to secure the buttress material to the anvil member.
 3. The surgical stapling device of claim 2, wherein the at least one roller includes first and second rollers and the at least one transverse slot includes first and second transverse slots.
 4. The surgical stapling device of claim 2, wherein the anvil member includes a proximal portion that defines a transverse channel, the first end of the buttress material received within the transverse channel when the buttress material is extended across the staple forming surface of the anvil member to secure the first end of the buttress material to the anvil member.
 5. The surgical stapling device of claim 2, wherein the at least one roller is supported for rotation within the elongate channel.
 6. The surgical stapling device of claim 2, wherein the at least one roller is fixedly supported within the elongate channel.
 7. An anvil assembly comprising: an anvil member and an anvil base, the anvil member including an inner staple forming surface and an outer surface, the outer surface defining an elongate channel, the anvil member secured to the anvil base to enclose the elongate channel, the anvil member including at least one roller positioned within the elongate channel, the at least one roller supporting a buttress material that is rolled about the at least one roller, the anvil member having a distal portion that defines at least one transverse slot that extends through the anvil member and communicates with the elongate channel, the buttress material having a first end that extends through the transverse slot, the buttress material being movable through the at least one transverse slot to a position atop the staple forming surface; and a cap supported on the anvil member, the cap being movable from an open position to a closed position, to provide access to the at least one roller and the buttress material, wherein the cap includes a distal portion that is pivotably coupled to the anvil member and a proximal surface that defines the at least one transverse slot, the cap engaging the buttress material in its closed position to secure the buttress material to the anvil member. 